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Job Procedures

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karthik
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0% found this document useful (0 votes)
62 views28 pages

Job Procedures

Uploaded by

karthik
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 28

Installation

Guide
FRAMED CABINETERY
Contents
Overview and warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Before you begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
What you will need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 1: Prepare the walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 2: Mark and measure walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 3: Locate wall studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 4: Installing wall cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Step 5: Installing blind corner wall cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 6: Installing diagonal corner wall cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 7: Joining face frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Step 8: Installing ceiling hung cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 9: Leveling wall cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 10: Installing base cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 11: Installing base cabinets with blind corner . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 12: Installing lazy susan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 13: Joining base cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 14: Leveling base cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 15: Installing countertop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 16: Adjusting cabinet doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Step 17: Decorative hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Final Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2
Keep In Mind : The beauty of real These instructions, while
hardwood comes from natural variations in
grain, texture, and color. Cabinet colors also accurate, may not address the
darken or lighten over time due to sunlight, many variations and exceptions
smoke, household cleaners, age and other
environmental conditions.
encountered while installing
Most cabinets are also constructed from cabinetry. To that end, we offer
several pieces, which each accept stain slightly these instructions as a guide to
differently. Neither these variations nor natural
grain and texture variations are considered proper cabinet installation.
reason for replacement. If you encounter variations in
Some of our door styles use solid wood center
your kitchen, please consult a
panels. Some expansion and contraction will
occur, depending on the season and humidity licensed professional.
levels. Painted surfaces will develop hairline
cracks at joints caused by seasonal humidity
changes and the expansion/contraction of
the wood. This is the nature of hardwood, and
hairline cracks on painted surfaces will not be
considered reason for replacement.

We reserve the right to substitute discontinued


product with the most similar styling, wood
species, and color available at the time a
warranty claim is submitted.

Should you have any further questions regarding


the care and maintenance of your cabinetry,
please contact your dealer.

For complete warranty information,


please visit your cabinetry brand’s website.

3
Before You Begin What you will need
• Chalkline
Please inspect ALL of the cabinetry for damages and color
• Countersink
variation before you begin to tear out your existing kitchen.
Report all issues at one time to your dealer and not as you • Electric drill with various bits

install the product. Multiple replacement requests will further • 4’ level


delay your project. Once received by acpi, replacement • 10’ or 12’ wood extension rule or tape
products will be ready to ship in 7 business days and will measure
ship via cycle truck to your dealer. Remember, installation of • Carpenter’s square 24" x 16"
the product indicates acceptance and will not be eligible for • Step ladder
replacement or credit.
• Screwdrivers

• Screws for countertop


(length depends on countertop and
First things first. SAFETY! shim thickness)

• Use safety glasses and work methodically. • Pan head sheet metal screws:

• Only use properly grounded electrical tools. • #8 x 3" for mounting wall
and base cabinets
• Keep the work area free of clutter.
• #10 x 3" with flatwashers
• If possible, create a flat raised surface on which to work/ for mounting ceiling hung
connect cabinets together. cabinets

• #8 x 2 1/2" for joining


face frames

• Wood shims

• Two 4" C-clamps or carpenter


style clamps

• Two 1x2x36" wood strips for


countertop support with
each base Lazy Susan

• 2x4 wall cleat or 2x4 T-brace for install-


ing wall cabinets

4
Step 1
Prepare the walls
Cabinets must be mounted plumb, level and square. Remove protruding objects
from the walls. With a level, check walls for high spots and remove them if possible;
otherwise shim cabinets during installation.
Use the level to find the highest point of the floor and mark this point along the walls.

5
Step 2
Measure and mark walls
From the mark on the wall that indicates the high point of the floor, measure 34-1/2"
up the wall; using a level, draw a horizontal line. This is the top height of the base
cabinets. Draw another horizontal line for the top of the wall cabinets (84", 87", 90",
93", 96" or 102" respectively for 30", 36" or 42" high wall cabinets).

6
Step 3
Locate wall studs
Cabinets must be attached to wall studs for support. Find the studs with a stud
finder, by tapping the wall with a hammer, or by driving a nail through the wall
board at a height that will later be covered by cabinets. Studs are usually 16 inches
apart. Draw a line on the wall at the center location of each stud.

7
Step 4
Installing wall cabinets

For ease of installation, remove doors from the cabinets by unscrewing the hinge
from the cabinet front frame. Set the doors aside, stacking them front to front to
avoid damage. Remove shelves. 

8
Step 4 - continued
Always install wall corner cabinets first
Use a T-brace or nail a 2x4 cleat to the wall at the proper height to support the cabinets
during installation. With the cabinet top placed at the line you marked on the wall,
transfer the location of the wall studs to the inside of the cabinet. Then, at the wall stud
marks, use a 3/32" twist drill bit to drill pilot holes
through the hanger rails in the back of the cabinet at
top and bottom. Drill these holes into the wall studs
also, to a depth of about 1-3/4". Use Wood Shims if
Needed at Screw
Location

Use a 3/16" twist drill bit to enlarge the holes in the


hanger rails only. Fasten the cabinet to the wall using
two #8 x 3" screws at top and bottom hanger rails.
It is important not to tighten screws completely until
cabinet has been shimmed as needed.
Do not use nails to install cabinets to wall.
Be sure to use a level to check against the
front, sides and bottom of each cabinet during
WALL
installation (see details in Step 9).
CO ABI

WALL
C

NOTE: When tightening hanger rails against a wall


RN NE

4' or 6' level


ER T

square tool

it is important not to apply so much torque on the


install screws that the hanger rails are compressed. Shim cabinet square
900
with walls so remaining
Doing so can cause the joint between hanger rail cabinets in the run fit
and cabinet to break, in time, the improperly installed proper

cabinet could fall off a wall.

9
Step 5
Installing blind corner wall cabinets
Proper installation of other cabinets will depend on level and square install of blind
corner cabinet. Blind corner wall cabinets can be installed up to 3" away from
adjoining wall, providing adequate clearance for cabinet doors. Hang blind corner
cabinets as described in Step 4, but a WF3 filler is required. Attach the filler to both
cabinets using the procedure for joining face frames outlined in Step 7.

filler

10
Step 6
Installing diagonal corner wall cabinets
These cabinets require 24 inches on each of two adjoining walls. When installing,
use your level to be sure cabinets are level vertically and horizontally and square
with remainder of the wall before securing to wall. Proper installation of other
cabinets will depend on squareness and level installation of the corner cabinet.

1" x 2" Wood


Furring Strip

Use Wood
Shims If Needed

Wood T-Brace

11
Step 7
Joining face frames
Make sure cabinet face frames are flush at top and bottom. Hold cabinets together
with C-clamps at top and bottom while installing. Use a 11/32" twist drill bit to drill a
hole part way through one cabinet stile (the vertical portion of the face frame) at top
and bottom.
At the center of these holes,
use a 1/8" twist drill bit to drill
a pilot hole the rest of the way
through the cabinet stile, about
1" into the adjoining cabinet
stile.
Fasten cabinets together with
#8 x 2-1/2" screws.
If necessary, shim between
wall and cabinet, then tighten face frame stiles
screws completely, making
sure screws go into studs at
least 1".
NOTE: Shorter screws may be
required for fillers that are to
be trimmed.

12
Step 8
Installing ceiling hung cabinets
Locate ceiling joists above wall cabinets (a minimum of 2 joists or proper anchor bolts
per cabinet). Using a 3/32" twist drill bit, drill four pilot holes through the top frame of
the cabinet, about 1-1/2" into the ceiling joist. Use a 3/16" twist drill bit to drill through
the top frame of cabinet only at the
pilot holes.

Fasten cabinets to ceiling using #10


x 3" screws. Use flat washers with
each screw to better distribute load
to prevent screw heads from pulling
through.

Join face frames using procedure in


Step 7.

washers

13
Step 9
Leveling wall cabinets
After hanging each wall cabinet, check with a level against the front, sides and bottom
of cabinet to ensure it is plumb and level. If necessary, shim between wall and cabinets
to correct for uneven walls. You may need to loosen screws slightly to insert shims. Shim
ceiling-hung cabinets as necessary between ceiling and cabinet. After alignment, tighten
all screws securely.

incorrect correct

incorrect correct

14
Step 10
Installing base cabinets
Install base cabinets after ceiling or wall-hung cabinets. For ease of
installation, remove doors from the cabinets by unscrewing the hinge from the
cabinet front frame.
Remove the drawers.
Set the doors aside, stacking them front to front to avoid damage. Remove shelves.
Start from one corner. Using a 1/8" twist drill bit, drill holes through the top rail at
back of cabinet at stud location marked on wall, about 1-1/2" into the stud.
Secure cabinet to the wall using #8 x 3" screws, making sure screws go into studs
at least 1". Use a level to check against front, sides and top of cabinet (see Step 14).
Shim between wall and cabinet at screw locations and between floor and cabinet
as necessary to keep cabinet plumb and level and aligned with base cabinet mark
on wall from Step 2.
NOTE: Tightening hanger rails against a crooked wall without shims can break joint
between hanger rail and cabinet.
When tightening hanger rails against a wall it is important not to apply so much
torque on the install screws that the hanger rails are compressed. Doing so can
cause the joint between hanger rail and cabinet to break.

15
Step 11
Installing base cabinets with blind corner
NOTE: Always start in the corner. Since each unit differs, check layout drawing
to determine proper distance from adjoining wall.
Position and secure cabinets using same procedure as for base cabinets (Step 10),
except that a BF3 filler is required.
Attach base filler to both base cabinets using procedure for joining face frames
(Step 7).

blind
cabin
et

inet
ining cab
adjo

This cabinet may require


being pulled from the wall.
Verify that this drawer has
enough clearance to open
The hardware on this cabinet completely after cabinets
may cause clearance issues filler are positioned.
with the blind cabinet door/
drawer, requiring that the
blind cabinet be pulled.

16
Step 12
Installing lazy susan base cabinet
Square and level installation assures smooth operation, as well as proper installation
of remaining cabinets. Provide support for the countertop in the corner behind the
Lazy Susan by securing two 36" lengths of 1x2 stock to the wall; level these two
pieces with the base cabinet mark from Step 2.

17
Step 13
Joining base cabinets
Make sure cabinet face frames are flush at top and bottom. Hold cabinets together
with C-clamps at top and bottom while installing. Use a 11/32" twist drill bit to drill a
hole part way through one cabinet stile (the vertical portion of the face frame) at top
and bottom.
At the center of these holes,
use a 1/8" twist drill bit to drill
a pilot hole the rest of the way
through the cabinet stile, about
1" into the adjoining cabinet
stile.
Fasten cabinets together with
#8 x 2-1/2" screws.
If necessary, shim between
wall and cabinet, then tighten face frame stiles
screws completely, making
sure screws go into studs at
least 1".
NOTE: Shorter screws may be
required for fillers that are to
be trimmed.

18
Step 14
Leveling base cabinets
Check each cabinet as it is attached
to wall, front to back and across front
edge with a level. Be certain cabinet
is level in both directions.
Shim between cabinet and floor or
between cabinet and wall to keep
base units level and plumb. Shim
between back rail and wall at screw
locations as necessary to prevent rail from bowing when secured to wall. Tighten all
screws.

incorrect correct

incorrect correct

19
Step 15
Installing countertop
base cabinet I-beam
Follow countertop manufacturer’s
instructions for proper installation. Base
cabinet I-beams should be utilized when
attaching countertop. Be careful to use
the proper length screw and not to over-
tighten, damaging the countertop. Screws
should be placed no further than 1" from
the front or back of the cabinet.

20
Step 16
Adjusting cabinet doors De
p th
Ad
jus
tm
e nt

Replace doors and drawers removed during installation and adjust as needed. Loosen
De
p th
Ad
jus
tm
e nt

vertical adjustment screw on each hinge. Align cabinet door to frame, then re-tighten
screws. Loosen horizontal adjustment screws, reducing gap between doors by moving
left or right, then tighten screws. Re-insert shelves at desired intervals.

Overlay Hinge
Height Adjustment

Height Adjustment

De
p th
Ad
jus
tm
e nt

t
en
stm
dju
eA
Sid
t
en
stm
dju
eA
Sid

Height Side Depth


Adjustment of the door up or Allows the door to be moved from Allows adjustment of the door
down, allowing alignment of door side to side giving you the ability closer to, or further away from the
tops and bottoms in relation to to adjust the gap on butt doors to face frame. This gives you the ability
the frame or as compared to the accommodate humidity changes in to compensate for any "racking" of
Height Adjustment

drawer front. the home. the cabinet box during installation.

Concealed Hinge (Inset)

t
en
stm
dju
eA
Sid

Height Side Depth


Adjustment of the door up or Allows the door to be moved from Allows adjustment of the door closer
down, allowing alignment of door side to side giving you the ability to, or further away from the face of the
tops and bottoms in relation to the to adjust the gap on butt doors to face frame. This gives you the ability
frame opening. accommodate humidity changes in to compensate for any "racking" of the
the home. cabinet box during installation.
21
Step 17
Decorative hardware
Install decorative knobs or pulls as desired.

22
Final Adjustments
All cabinets require final adjustments after
initial installation.

23
Problem:
Door does not close properly against cabinet face frame at
either top or bottom.

Solution:
This could be a result of improper adjustment of door hinges, the cabinet is not installed
"square," or door warping due to insufficient or excessive humidity. Loosen mounting
screws and shim to make cabinet plumb, level and square. Loosen hinge screws and
readjust. If necessary, install humidity control to keep relative humidity to 35%.

24
Problem:
Space between two butt doors exceeds 1/8" or is uneven
or doors do not line up properly.

Solution:
Your cabinet may not be installed level, or door hinges are not correctly adjusted.
Always use a level on horizontal and vertical surfaces.

overlay doors

inset doors

25
Problem:
Drawer does not close evenly or drawer movement in/out is
stiff.

Solution:
Check guides to ensure they are free of sawdust or foreign objects that may
obstruction guide operation. Ensure guide moves left and right on socket and check
that drawer guides are engaged with locking device and are fully operational.

Drawer Box Placement:


Place drawer box on
runners and close; drawer
will automatically engage
runners.

26
Problem:
Drawer front does not fit flush with cabinet.

Solution:
Cabinet may not be installed level. Loosen mounting screws and shim to make
cabinet plumb and level. Check that drawer guides are engaged with locking device
and are fully operational.

Move drawer guide member


left or right within socket as
needed.

27
Problem:
Drawer front is crooked.

Solution:
Press up on adjustment latch and slide forwards or backwards. To raise drawer, slide
towards back of cabinet; to lower, slide towards front of cabinet.

Vertical Adjustment of
Drawer Front:
Press up on adjustment latch and
slide forwards or backwards. To
raise drawer, slide towards back of
cabinet; to lower, slide towards front
of cabinet.

overlay

For Drawer Guides with


Tilt Adjustment:
Rotate adjustment lever on rear of
each guide to adjust tilt of drawer
front.

inset

28

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